Digital Light Projector Research Articles

It's not just a phase: shaping the future of 3D photoprinted polymers with polymerization‐induced phase separation

AbstractAdditive manufacturing is a technology that promises to disrupt the conventional manufacturing industry due to its ability to create complex structures with improved macroscopic control not available with existing techniques like molding or milling. In addition to superior macroscopic structural control, photoprinting methods such as digital light projection can enable molecular‐scale control over the fabrication process by taking advantage of the self‐sorting or assembly properties of the monomers themselves. Polymerization‐induced phase separation (PIPS) allows for the remarkable introduction of microscopic control into additive manufacturing, using polymer‐rich and polymer‐poor regions that rely on incompatibilities to phase separate during polymerization creating new complex materials not achieved by traditional methods. With the incorporation of porogens or filler materials, microporosity and/or surface functionalization can be introduced in a facile one‐step printing process. This expands the potential applications of 3D printed materials, to include micro‐ and macroscale structural control. Using PIPS as a design strategy, polymeric materials with previously unprecedented capabilities can be produced with ease enabling 3D printing to grow into its full potential as a manufacturing tool. © 2024 Society of Chemical Industry.

Dynamic three-dimensional reconstruction with phase shift coding division multiplexing

Fringe projection profilometry with temporal phase unwrapping (FPP-TPU) has been gotten more and more attention in reconstructing the object with complex surfaces. However, a general contradiction in the existing FPP-TPUs is that more auxiliary coded patterns may limit sampling rate in dynamic three-dimensional (3D) measurement. In this paper, inheriting the single-frame auxiliary pattern of the phase-shifting temporal phase unwrapping (PS-TPU), an improved phase shift coding temporal phase unwrapping with higher robustness is proposed. And new projection stratagem with phase shift coding division multiplexing (PSC-DM) is also proposed to enhance the reconstructing rate in dynamic 3D scene. Firstly, six codewords instead of the traditional eight codewords are embedded into the single-frame auxiliary coding pattern, which guarantees the decoding robustness and provides a faster decoding process with single-step direction unifying. Then, the new projection sequence stratagem is designed with every two sets of 3-step phase-shifting patterns projection followed by the single-frame phase-shifting coding pattern projection. During phase unwrapping, every adjacent three frames of phase-shifting pattern sequentially resolving a wrapped phase and a highly robust 3D reconstruction can be achieved by using the closest phase-shifting coding pattern so as to achieve phase-shifting coding division multiplexing. It can obtain higher reconstructing rate. In addition, a phase shift segmentation is used to correct mismatched errors of fringe order. The experimental results demonstrate that the proposed method can increase the reconstructing rate from the rate of 30 fps in traditional PS-TPU method to 68.57 fps at the digital light projector (DLP) projection rate of 120 fps, which shows its potential prospective in dynamic 3D shape reconstruction.

Effect of Surface Treatments Applied to 3D Printed Permanent Resins on Shear Bond Strength.

3D-printed permanent resins have recently been introduced to produce permanent restorations. The aim of this study is to evaluate the effect of surface treatment methods on the shear-bond strength (SBS) between 3D-printed permanent resins and adhesive cement. In this study, samples were produced using digital light projection (DLP) and stereolithography (SLA) 3D printers with two permanent resins (Crowntec, Saremco and Permanent Crown, Formlabs) in accordance with manufacturer guidelines. The samples were separated into three groups: sandblasting, hydrofluoric acid and no surface treatment. The surface profile (Ra, Sa) of the samples was examined with a confocal microscope (Smartproof 5, Zeiss). Then, a self-adhesive resin cement was applied to the samples in a transparent mold (2.38 mm diameter) in accordance with ISO 29022:2013. A universal testing machine was used to perform SBS test. A stereomicroscope was used to analyze the different types of fractures. A two-way analysis of variance (ANOVA) test was used to assess the data (p<0.05). The samples with sandblasting applied to the surface showed higher surface roughness values than the samples with hydrofluoric acid (p<0.001). 3D printer technology and surface treatment methods affected SBS values (p<0.001). Sandblasting groups higher SBS values were than in the hydrofluoric acid group (p<0.001). Sandblasting revealed cohesion fractures, which indicated a stronger bond, while hydrofluoric acid displayed adhesive and mix fractures. When sandblasting was applied to the surface of the samples prepared using permanent resins, higher adhesion was achieved with adhesive cement. Key words:3D printing, Shear bond strength, Sandblasting, Stereolithography.

Light-regulated soliton dynamics in liquid crystals

Electrically powered solitons are particle-like field configurations in out-of-equilibrium nematics that have garnered significant interest. However, their random generation and lack of controllable motion have limited their application. Here, we present a reconfigurable optoelectronic approach capable of regulating the entire lifecycle of solitons by utilizing multi-strategy digital light projection to construct delicate patterning of virtual electrode. We demonstrate that optically actuated domains with diverse geometry enable the generation of multiple solitons and further allow in-situ formation of individual soliton by matching the light pattern to its dimension. Exquisitely engineered light intensity of patterns facilitates modulation of soliton velocity and transformation of propagating direction. The utilization of a light-guided channel enables the on-demand control of soliton trajectories along customized paths. Furthermore, dynamic light patterns that vary in space and time allow for collective motion such as migration, mimicking phototaxis in biological systems. This reconfigurable manipulation strategy, grounded in the photoconductive effect, proves highly versatile and effective in directing soliton dynamics, heralding the potential for their programmable control and offering a significant advantage in multitasking scenarios.

Deep-learning-enabled temporally super-resolved multiplexed fringe projection profilometry: high-speed kHz 3D imaging with low-speed camera

AbstractRecent advances in imaging sensors and digital light projection technology have facilitated rapid progress in 3D optical sensing, enabling 3D surfaces of complex-shaped objects to be captured with high resolution and accuracy. Nevertheless, due to the inherent synchronous pattern projection and image acquisition mechanism, the temporal resolution of conventional structured light or fringe projection profilometry (FPP) based 3D imaging methods is still limited to the native detector frame rates. In this work, we demonstrate a new 3D imaging method, termed deep-learning-enabled multiplexed FPP (DLMFPP), that allows to achieve high-resolution and high-speed 3D imaging at near-one-order of magnitude-higher 3D frame rate with conventional low-speed cameras. By encoding temporal information in one multiplexed fringe pattern, DLMFPP harnesses deep neural networks embedded with Fourier transform, phase-shifting and ensemble learning to decompose the pattern and analyze separate fringes, furnishing a high signal-to-noise ratio and a ready-to-implement solution over conventional computational imaging techniques. We demonstrate this method by measuring different types of transient scenes, including rotating fan blades and bullet fired from a toy gun, at kHz using cameras of around 100 Hz. Experiential results establish that DLMFPP allows slow-scan cameras with their known advantages in terms of cost and spatial resolution to be used for high-speed 3D imaging tasks.

Optimizing polymethyl methacrylate (PMMA)-based stretchable microneedle arrays by vat photopolymerization for efficient drug loading

Advancements in vat photopolymerization printing technology have enabled the fabrication of components with varying mechanical properties within a single print job. Using a digital light projector to cure photopolymer resins layer by layer, it allows the fabrication of parts with both flexibility and rigidity, in different regions. It simplifies the manufacturing process by eliminating the need for multiple steps. Specifically, for applications such as microneedles, printing onto a stretchable substrate is crucial compared to a rigid substrate, as it conforms better to the contours of the skin, ensuring more effective and comfortable drug delivery. However, a notable limitation of vat photopolymerization printing is the current lack of biocompatible materials, which restricts its application for microneedle fabrication. The challenge lies in developing materials that meet biocompatibility standards, while also being compatible with the printing technique and capable to achieve precise microscale structures. Therefore, we have developed an ultraviolet (UV)-curable polymethyl methacrylate (PMMA) suitable for the vat photopolymerization printing and the microneedles were designed to have a hollow side structure, enhancing drug loading efficiency. Comprehensive testing has been conducted, including durability test, drug loading efficiency, and skin penetration capability.

High value-added use of waste photosensitive polyimide to develop low-shrinkage UV-curable inks for digital light projection technology

In the mass industrial production process of polyimide photoresists, waste generation is inevitable due to unqualified molecular weights, inappropriate ionic content of resins, or storage expiration. Consequently, the recycling and reuse of waste photosensitive polyimide (w-PSPI) is a growing concern in both scientific and industrial communities. In this work, w-PSPI was explored to prepare photocurable, fully crosslinked inks for digital light projection technology (DLP). For this purpose, suitable photoactive solvents and crosslinking agents were first screened to overcome the issue of large shrinkage caused by solvent volatilization. The formation of cross-linked network structures during DLP processing and subsequent imidization was also investigated. As a result, a polyimide DLP ink with minimum size shrinkage (less than 5 %) was proposed. For a given active solvent, the mechanical behavior and heat resistance of DLP-formed objects were significantly influenced by the ratio of short-chain and long-chain crosslinkers and the imidization temperature. By optimizing ink composition and imidization temperature, the DLP-formed objects showed high heat resistance (Td5 > 385 °C, Tg > 150 °C) and balanced mechanical properties of strength and toughness (Modulus ≥1 GPa, elongation at break >5 %). This w-PSPI ink has been successfully utilized to manufacture several complex 3D structures and vertical 3D microarrays with 100-µm on a limited-resolution DLP printer. This study not only points the direction for the high-added utilization of w-PSPI but also demonstrates the potential for expanding PSPI application from 2D lithography to 3D micro-manufacturing.

Structural tuning of anisotropic mechanical properties in 3D-Printed hydrogel lattices

We investigated the ability to tune the anisotropic mechanical properties of 3D-printed hydrogel lattices by modifying their geometry (lattice strut diameter, unit cell size, and unit cell scaling factor). Many soft tissues are anisotropic and the ability to mimic natural anisotropy would be valuable for developing tissue-surrogate “phantoms” for elasticity imaging (shear wave elastography or magnetic resonance elastography). Vintile lattices were 3D-printed in polyethylene glycol di-acrylate (PEGDA) using digital light projection printing. Two mechanical benchtop tests, dynamic shear testing and unconfined compression, were used to measure the apparent shear storage moduli (G′) and apparent Young's moduli (E) of lattice samples. Increasing the unit cell size from 1.25 mm to 2.00 mm reduced the Young's and shear moduli of the lattices by 91% and 85%, respectively. Decreasing the strut diameter from 300 μm to 200 μm reduced the apparent shear moduli of the lattices by 95%. Increasing the geometric scaling ratio of the lattice unit cells from 1.00 × to 2.00 × increased mechanical anisotropy in shear (by a factor of 3.1) and in compression (by a factor of 2.9). Both simulations and experiments show that the effects of unit cell size and strut diameter are consistent with power law relationships between volume fraction and apparent elastic moduli. In particular, experimental measurements of apparent Young's moduli agree well with predictions of the theoretical Gibson-Ashby model. Thus, the anisotropic mechanical properties of a lattice can be tuned by the unit cell size, the strut diameter, and scaling factors. This approach will be valuable in designing tissue-mimicking hydrogel lattice-based composite materials for elastography phantoms and tissue engineered scaffolds.

Reinforcement induced microcracking during the conversion of polymer-derived ceramics

This study investigates the role of discontinuous reinforcement on the microcracking of a preceramic polymer matrix during polymer to ceramic conversion. The material system comprised a carbosilane-based, preceramic polymer reinforced with mullite particles. The preceramic resin slurry was formulated for photopolymerization on a digital light projection 3D printer. Micro X-ray computed tomography, using a synchrotron light source, monitored a printed composite part during pyrolysis. The conversion of the carbosilane matrix into Si(O)C generated microcracks in the matrix that radially extended from particles. The likelihood of microcrack formation positively correlated with particle size. The largest particles (>104 µm3 volume or >60 µm side length) always abutted microcracks, while the matrix surrounding smaller particles (<5 µm) was free of microcracks. Numerical calculations showed the particles resist the shrinking matrix during its conversion. This created tensile stresses within the matrix. The driving force for microcrack growth was also analyzed with regard to the influence of matrix material parameters, particle form-factor and crack length. These results reveal the need to consider the form factor of discontinuous reinforcements, with regard to the material properties of the polymer-derived ceramic, in order to reduce or eliminate defects in the final part.

Droplet bioprinting of acellular and cell-laden structures at high-resolutions

Advances in digital light projection(DLP) based (bio) printers have made printing of intricate structures at high resolution possible using a wide range of photosensitive bioinks. A typical setup of a DLP bioprinter includes a vat or reservoir filled with liquid bioink, which presents challenges in terms of cost associated with bioink synthesis, high waste, and gravity-induced cell settling, contaminations, or variation in bioink viscosity during the printing process. Here, we report a vat-free, low-volume, waste-free droplet bioprinting method capable of rapidly printing 3D soft structures at high resolution using model bioinks and model cells. A multiphase many-body dissipative particle dynamics model was developed to simulate the dynamic process of droplet-based DLP printing and elucidate the roles of surface wettability and bioink viscosity. Process variables such as light intensity, photo-initiator concentration, and bioink formulations were optimized to print 3D soft structures (∼0.4–3 kPa) with a typical layer thickness of 50 µm, an XY resolution of 38 ± 1.5 μm and Z resolution of 237 ± 5.4 µm. To demonstrate its versatility, droplet bioprinting was used to print a range of acellular 3D structures such as a lattice cube, a Mayan pyramid, a heart-shaped structure, and a microfluidic chip with endothelialized channels. Droplet bioprinting, performed using model C3H/10T1/2 cells, exhibited high viability (90%) and cell spreading. Additionally, microfluidic devices with internal channel networks lined with endothelial cells showed robust monolayer formation while osteoblast-laden constructs showed mineral deposition upon osteogenic induction. Overall, droplet bioprinting could be a low-cost, no-waste, easy-to-use, method to make customized bioprinted constructs for a range of biomedical applications.

Optimizing the parameters of spherical harmonic reconstruction of the 3D morphology of manufactured aggregate with different particle sizes

The optimal reconstruction parameters of spherical harmonic (SH) series for the aggregates with different morphologies and sizes were not clear. In this paper, manufactured aggregates with different sizes (1.18–2.36 mm, 2.36–4.75 mm, 4.75–9.50 mm), and natural aggregate with size >1.18 mm were scanned using the digital light projection (DLP), and reconstructed using SH series. The effect of maximum number of SH functions (N) used in the reconstruction series and the number of terms in the Gaussian quadrature (G) used for solving the SH expansion coefficients on the reconstruction errors were studied. The optimal reconstruction parameters for different particle sizes and morphologies were proposed, via a derived relationship between N and G. The reconstruction errors decreased when the N and G values increased. The relationship between N and G was derived to be G ≥ 1.84 N + 3.60, which is probably caused by the issue of the algebraic precision of the Gaussian integral.

Controlled Mechanical Property Gradients Within a Digital Light Processing Printed Hydrogel-Composite Osteochondral Scaffold.

Tissue engineered scaffolds are needed to support physiological loads and emulate the micrometer-scale strain gradients within tissues that guide cell mechanobiological responses. We designed and fabricated micro-truss structures to possess spatially varying geometry and controlled stiffness gradients. Using a custom projection microstereolithography (μSLA) system, using digital light projection (DLP), and photopolymerizable poly(ethylene glycol) diacrylate (PEGDA) hydrogel monomers, three designs with feature sizes < 200μm were formed: (1) uniform structure with 1MPa structural modulus ( ) designed to match equilibrium modulus of healthy articular cartilage, (2) = 1MPa gradient structure designed to vary strain with depth, and (3) osteochondral bilayer with distinct cartilage ( = 1MPa) and bone ( = 7MPa) layers. Finite element models (FEM) guided design and predicted the local mechanical environment. Empty trusses and poly(ethylene glycol) norbornene hydrogel-infilled composite trusses were compressed during X-ray microscopy (XRM) imaging to evaluate regional stiffnesses. Our designs achieved target moduli for cartilage and bone while maintaining 68-81% porosity. Combined XRM imaging and compression of empty and hydrogel-infilled micro-truss structures revealed regional stiffnesses that were accurately predicted by FEM. In the infilling hydrogel, FEM demonstrated the stress-shielding effect of reinforcing structures while predicting strain distributions. Composite scaffolds made from stiff μSLA-printed polymers support physiological load levels and enable controlled mechanical property gradients which may improve in vivo outcomes for osteochondral defect tissue regeneration. Advanced 3D imaging and FE analysis provide insights into the local mechanical environment surrounding cells in composite scaffolds.

Sustainable Vat Photopolymerization-Based 3D-Printing through Dynamic Covalent Network Photopolymers.

Vat photopolymerization (VPP) based three-dimensional (3D) printing, including stereolithography (SLA) and digital light projection (DLP), is known for producing intricate, high-precision prototypes with superior mechanical properties. However, the challenge lies in the non-recyclability of covalently crosslinked thermosets used in these printing processes, limiting the sustainable utilization of printed prototypes. This review paper examines the recently explored avenue of VPP 3D-printed dynamic covalent network (DCN) polymers, which enable reversible crosslinks and allow for the reprocessing of printed prototypes, promoting sustainability. These reversible crosslinks facilitate the rearrangement of crosslinked polymers, providing printed polymers with chemical/physical recyclability, self-healing capabilities, and degradability. While various mechanisms for DCN polymer systems are explored, this paper focuses solely on photocurable polymers to highlight their potential to revolutionize the sustainability of VPP 3D printing.

3D printed porous membrane integrated devices to study the chemoattractant induced behavioural response of aquatic organisms.

Biological models with genetic similarities to humans are used for exploratory research to develop behavioral screening tools and understand sensory-motor interactions. Their small, often mm-sized appearance raises challenges in the straightforward quantification of their subtle behavioral responses and calls for new, customisable research tools. 3D printing provides an attractive approach for the manufacture of custom designs at low cost; however, challenges remain in the integration of functional materials like porous membranes. Nanoporous membranes have been integrated with resin exchange using purpose-designed resins by digital light projection 3D printing to yield functionally integrated devices using a simple, economical and semi-automated process. Here, the impact of the layer thickness and layer number on the porous properties - parameters unique for 3D printing - are investigated, showing decreases in mean pore diameter and porosity with increasing layer height and layer number. From the same resin formulation, materials with average pore size between 200 and 600 nm and porosity between 45% and 61% were printed. Membrane-integrated devices were used to study the chemoattractant induced behavioural response of zebrafish embryos and planarians, both demonstrating a predominant behavioral response towards the chemoattractant, spending >85% of experiment time in the attractant side of the observation chamber. The presented 3D printing method can be used for printing custom designed membrane-integrated devices using affordable 3D printers and enable fine-tuning of porous properties through adjustment of layer height and number. This accessible approach is expected to be adopted for applications including behavioural studies, early-stage pre-clinical drug discovery and (environmental) toxicology.

DLP fabrication of HA scaffold with customized porous structures to regulate immune microenvironment and macrophage polarization for enhancing bone regeneration

The immune microenvironment plays a pivotal role in osteoanagenesis. Biomaterials can modulate osteogenic efficacy by inducing specific local immune reactions. As 3D-printing technology advances, digital light projection printing has emerged as a promising method for creating large scale, high-precision biomaterial scaffolds. By adjusting the solid content and the sintering conditions during printing, the pore size of biomaterials can be meticulously controlled. Yet, the systematic influence of pore size on the immune microenvironment remains uncharted. We fabricated 3D-printed hydroxyapatite bioceramic scaffolds with three distinct pore sizes: 400 μm, 600 μm, and 800 μm. Our study revealed that scaffolds with a pore size of 600 μm promote macrophage M2 polarization, which is achieved by upregulating interferon−beta and HIF-1α production. When these materials were implanted subcutaneously in rats and within rabbit skulls, we observed that the 600 μm scaffolds notably improved the long-term inflammatory response, fostered vascular proliferation, and augmented new bone growth. This research paves the way for innovative therapeutic strategies for treating large segmental bone defects in clinical settings.

A novel perfusion bioreactor promotes the expansion of pluripotent stem cells in a 3D-bioprinted tissue chamber

While the field of tissue engineering has progressed rapidly with the advent of 3D bioprinting and human induced pluripotent stem cells (hiPSCs), impact is limited by a lack of functional, thick tissues. One way around this limitation is to 3D bioprint tissues laden with hiPSCs. In this way, the iPSCs can proliferate to populate the thick tissue mass prior to parenchymal cell specification. Here we design a perfusion bioreactor for an hiPSC-laden, 3D-bioprinted chamber with the goal of proliferating the hiPSCs throughout the structure prior to differentiation to generate a thick tissue model. The bioreactor, fabricated with digital light projection, was optimized to perfuse the interior of the hydrogel chamber without leaks and to provide fluid flow around the exterior as well, maximizing nutrient delivery throughout the chamber wall. After 7 days of culture, we found that intermittent perfusion (15 s every 15 min) at 3 ml min−1 provides a 1.9-fold increase in the density of stem cell colonies in the engineered tissue relative to analogous chambers cultured under static conditions. We also observed a more uniform distribution of colonies within the tissue wall of perfused structures relative to static controls, reflecting a homogeneous distribution of nutrients from the culture media. hiPSCs remained pluripotent and proliferative with application of fluid flow, which generated wall shear stresses averaging ∼1.0 dyn cm−2. Overall, these promising outcomes following perfusion of a stem cell-laden hydrogel support the production of multiple tissue types with improved thickness, and therefore increased function and utility.

Fringe projector with submillimeter fringe spacing at a meter-scale field of view.

State-of-the-art fringe projection systems generate fringe patterns using digital light projectors (DLP). The axial uncertainty is limited by the smallest fringe period and is directly related to the pixel count. This results in limited accuracy of current DLP systems that affect applications such as in situ measurements for laser powder bed fusion systems, where a submillimeter fringe period is needed for field-of views larger than 500m m×500m m. This work presents a scalable fringe projection technique that enables the generation of stable fringe patterns over a large field of view spanning several meters while maintaining submillimeter fringe periods. This system uses geometric phase gratings to enable variable fringe spacing and fringe orientation capabilities. The system shears a coherent beam in the Fourier plane using a pair of geometric polarization gratings. The separation between the gratings directly affects the fringe spacing, and the orientation of the gratings affects the fringe orientation. The depth of focus is only limited by the coherence of the light source, enabling high fringe periods even on tilted planes. The system is designed with a single path configuration, making the system more robust to environmental noise. With a rotating linear polarizer, we demonstrate that phase-shifting methods could be employed to acquire phase information about the object. This paper employs a single-shot Fourier transform phase estimation technique to process the intensity maps acquired using projected fringe patterns. Further, we demonstrate the capabilities of the system to produce submillimeter fringe spacing and the ability to project fringes on larger scales for measurements.

Topology Optimization for Digital Light Projector Additive Manufacturing Addressing the In-Situ Structural Strength Issue.

A topology optimization approach is proposed for the design of self-supporting structures for digital light projector (DLP) 3D printing. This method accounts for the adhesion forces between the print part and the resin base during DLP printing to avoid failure of the part due to stress concentration and weak connections. Specifically, the effect of the process-related adhesion forces is first simulated by developing a design variable-interpolated finite element model to capture the intricate mechanical behavior during DLP 3D printing. Guided by the process model, a stress-constrained topology optimization algorithm is formulated with both the SIMP and RAMP interpolation schemes. The interpolations on the stress term and the design-dependent adhesion load are carefully investigated. A sensitivity result on the P-norm stress constraint is fully developed. Finally, the approach is applied to several 2D benchmark examples to validate its efficacy in controlling the process-caused peak P-norm stresses. The effects of alternating between the SIMP and RAMP interpolations and changing the stress upper limits are carefully explored during the numerical trials. Moreover, 3D printing tests are performed to validate the improvement in printability when involving the process-related P-norm stress constraint.

Four-Dimensional Micro/Nanorobots via Laser Photochemical Synthesis towards the Molecular Scale.

Miniaturized four-dimensional (4D) micro/nanorobots denote a forerunning technique associated with interdisciplinary applications, such as in embeddable labs-on-chip, metamaterials, tissue engineering, cell manipulation, and tiny robotics. With emerging smart interactive materials, static micro/nanoscale architectures have upgraded to the fourth dimension, evincing time-dependent shape/property mutation. Molecular-level 4D robotics promises complex sensing, self-adaption, transformation, and responsiveness to stimuli for highly valued functionalities. To precisely control 4D behaviors, current-laser-induced photochemical additive manufacturing, such as digital light projection, stereolithography, and two-photon polymerization, is pursuing high-freeform shape-reconfigurable capacities and high-resolution spatiotemporal programming strategies, which challenge multi-field sciences while offering new opportunities. Herein, this review summarizes the recent development of micro/nano 4D laser photochemical manufacturing, incorporating active materials and shape-programming strategies to provide an envisioning of these miniaturized 4D micro/nanorobots. A comparison with other chemical/physical fabricated micro/nanorobots further explains the advantages and potential usage of laser-synthesized micro/nanorobots.

Rapid Micromolding of Sub-100 µm Microfluidic Channels Using an 8K Stereolithographic Resin 3D Printer.

Engineering microfluidic devices relies on the ability to manufacture sub-100 micrometer fluidic channels. Conventional lithographic methods provide high resolution but require costly exposure tools and outsourcing of masks, which extends the turnaround time to several days. The desire to accelerate design/test cycles has motivated the rapid prototyping of microfluidic channels; however, many of these methods (e.g., laser cutters, craft cutters, fused deposition modeling) have feature sizes of several hundred microns or more. In this paper, we describe a 1-day process for fabricating sub-100 µm channels, leveraging a low-cost (USD 600) 8K digital light projection (DLP) 3D resin printer. The soft lithography process includes mold printing, post-treatment, and casting polydimethylsiloxane (PDMS) elastomer. The process can produce microchannels with 44 µm lateral resolution and 25 µm height, posts as small as 400 µm, aspect ratio up to 7, structures with varying z-height, integrated reservoirs for fluidic connections, and a built-in tray for casting. We discuss strategies to obtain reliable structures, prevent mold warpage, facilitate curing and removal of PDMS during molding, and recycle the solvents used in the process. To our knowledge, this is the first low-cost 3D printer that prints extruded structures that can mold sub-100 µm channels, providing a balance between resolution, turnaround time, and cost (~USD 5 for a 2 × 5 × 0.5 cm3 chip) that will be attractive for many microfluidics labs.